Numerical Simulation and Sensitivity Evaluation of Process Parameters for AC-HVOF Spraying 3D Model

As one of the process methods on surface strengthening for parts, activated combustion high-velocity air-fuel (AC-HVAF) spraying technology is widely used. It is significant to quantitively reveal the flame evolution law of the AC-HVOF spraying process with a three-dimensional perspective, which improves the quality and cost performance of the coatings. In this study, computational fluid dynamics (CFD) was used to establish a three-dimensional model of the process. The combustion reaction of the propane and hydrogen was simulated by a one-step chemical model and an eddy dissipation model (EDM). The flight behavior of WC-12Co particles in the flow field was tracked based on the Lagrange method. The evolution characteristics of flame flow in the spraying were analyzed. The change laws of the pressure, temperature, and velocity during AC-HVAF spraying have been revealed in detail. On this basis, the response surface model (RSM) was designed by the Box–Behnen design (BBD) method. The response surface equation was combined with Monte Carlo sampling, which calculated the sensitivity of the particle deposition temperature and velocity in different process parameters. The results show that the oxygen/fuel ratio significantly influences the particle temperature and velocity.